Gilera NEXUS 300 i.e. User manual

GILERA WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this booklet to help you to get the very best from your scooter. Please read it carefully before riding
the scooter for the first time. It contains information, tips and precautions for using your scooter. It also describes features, details and devices to assure
you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle and it will serve you
well for a long time to come. This booklet forms an integral part of the scooter; should the scooter be sold, it must be transferred to the new owner.
NEXUS 300 i.e.
Ed. 2

The instructions given in this manual are intended to provide a clear, simple guide to using your scooter; this booklet also details routine maintenance
procedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre. The booklet also contains
instructions for simple repairs. Any operations not specifically described in this manual require the use of special tools and/or particular technical
knowledge: to carry out these operations refer to any authorised Dealer of Service Centres.
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Personal safety
Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment
Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-
aging the environment.
Vehicle intactness
The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
The signs that you see on this page are very important. They are used to highlight those
parts of the booklet that should be read with particular care. As you can see, each sign
consists of a different graphic symbol, making it quick and easy to locate the various
topics.
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INDEX
VEHICLE...................................................................................... 7
Dashboard................................................................................ 9
Instruments............................................................................... 11
Indicator unir............................................................................. 11
Clock......................................................................................... 12
Digital lcd display...................................................................... 13
Maintenance icons................................................................ 14
Setting the total and trip odometers...................................... 15
Setting the date function........................................................ 15
*MODE* button...................................................................... 15
Key switch................................................................................. 16
Locking the steering wheel.................................................... 17
Releasing the steering wheel................................................ 17
Switch direction indicators........................................................ 18
Horn button............................................................................... 18
Light switch............................................................................... 18
Start-up button.......................................................................... 19
Engine stop button.................................................................... 19
The immobilizer system............................................................ 19
Keys...................................................................................... 20
Immobilizerdevice enabled indicator led............................... 21
Operation............................................................................... 21
Programming the immobilizer system................................... 22
Accessing the fuel tank............................................................. 23
Power supply socket................................................................. 23
The saddle................................................................................ 24
Identification.............................................................................. 24
Adjusting the windscreen.......................................................... 26
USE.............................................................................................. 29
Checks...................................................................................... 30
Refuelling.................................................................................. 31
Tyre pressure............................................................................ 31
Shock absorbers adjustment.................................................... 33
Running in................................................................................. 34
Starting up the engine............................................................... 35
Precautions........................................................................... 36
Difficult start up......................................................................... 37
Stopping the engine.................................................................. 37
Stand......................................................................................... 38
Automatic transmission............................................................. 39
Safe driving............................................................................... 39
MAINTENANCE........................................................................... 43
Engine oil level.......................................................................... 44
Engine oil level check............................................................ 44
Engine oil top-up................................................................... 45
Warning light (insufficient oil pressure)................................. 45
Engine oil change.................................................................. 45
Hub oil level.............................................................................. 47
Tyres......................................................................................... 49
Spark plug dismantlement........................................................ 50
Removing the air filter............................................................... 51
Air filter cleaning....................................................................... 52
Cooling fluid level...................................................................... 52
Checking the brake oil level...................................................... 54
Braking system fluid top up................................................... 54
Battery....................................................................................... 56
Use of a new battery............................................................. 56
Long periods of inactivity.......................................................... 57
Fuses........................................................................................ 57
Front light group........................................................................ 62
Headlight adjustment............................................................. 63
Front direction indicators........................................................... 64
Rear turn indicators................................................................... 65
Number plate light..................................................................... 66
Helmet compartment lighting bulb............................................ 66
Brake light................................................................................. 67
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Rear-view mirrors...................................................................... 68
Front and rear disc brake.......................................................... 68
Puncture.................................................................................... 70
Periods of inactivity................................................................... 71
Cleaning the vehicle.................................................................. 71
TECHNICAL DATA...................................................................... 77
Kit equipment............................................................................ 82
SPARE PARTS AND ACCESSORIES........................................ 83
Warnings................................................................................... 84
PROGRAMMED MAINTENANCE............................................... 87
Scheduled maintenance table................................................... 88
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NEXUS 300
i.e.
Chap. 01
Vehicle
7

01_01
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Dashboard (01_01)
A= Ignition key-switch
B= Starter button
C= Throttle grip
D= Front brake lever
E= «Mode» remote switch
F= Emergency cut-off switch
G= Digital instrument panel
H= Warning light unit on digital instrument panel
I= Analogue instrument panel
L= Passing
M= Rear brake lever
N= Light switch
O= Turn indicator switch
P= Horn button
Q= Warning light unit
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01_02
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Instruments (01_02)
A= Rpm indicator
B= Speedometer with twin scale (km/h and mph)
C= Engine control warning light
D= Low fuel warning light
M= Low oil pressure warning light
F= Turn indicator warning light
G= Antitheft device LED
H= LCD Display
I= «Odo/Set» button
L= «Clock» button
M= «Mode» button
01_03
Indicator unir (01_03)
A= Warning light pre-installation
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B= Headlight warning light
C= High-beam warning light
D= Warning light pre-installation
01_04
Clock (01_04)
Pressing the button«CLOCK» less than 1 second displays the following sequence:
•TIME
•DATE
•TOTAL/PARTIAL
To set the clock push and hold the «CLOCK» button for longer than 3 seconds.
The numbers showing the hours will begin flashing.
Set the hours with the «ODO/SET» button. Push the «CLOCK» button again and the
minutes numbers start flashing.
Set the minutes with the «ODO/SET» button. Press the «CLOCK» button again to
start the clock moving normally.
During the reset process, not pressing any buttons longer than 8 seconds ends the
process automatically and the display shows the modified time.
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01_05
Digital lcd display (01_05)
A= «SERVICE» maintenance icon
B= «BELT» maintenance icon
C= Battery Icon
D= Miles/gallons icon (Not used)
E= 3-digit display
F= Fuel gauge
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G= Miles per hour icon
H= Total odometer indicator
I= Partial odometer indicator
L= «ODO/SET» button
M= Km/h gauge
N= «CLOCK» button
O= 5-digit display
P= «MODE» button
Q= Maximum speed indicator
R= Mean speed
S= Water temperature gauge
01_06
Maintenance icons (01_06)
The icons signal the user that scheduled maintenance operations should be carried
out.
The flashing «A» SERVICE or «B» BELT icons signal the need to carry out the sched-
uled maintenance service, according to the intervals specified in the Scheduled
Maintenance Table.
In any case, vehicle maintenance must be carried out at the service intervals recom-
mended in the Scheduled Maintenance.
WARNING
REFER TO THE «SCHEDULED MAINTENANCE TABLE» FOR FURTHER MAIN-
TENANCE OPERATIONS
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Setting the total and trip odometers
By pressing the button «L» ODO/SET, the display shifts from total to trip odometer.
Hold down the button «L» ODO/SET for more than 3 seconds to reset the trip odom-
eter, mean speed and maximum speed gauges.
01_07
Setting the date function (01_07)
Set «DATE» with the «CLOCK» button. Hold down the «CLOCK» button longer than
3 seconds and the year numbers start flashing. Set the year with the «ODO/SET»
button. Push the «CLOCK» button again and the month numbers@ start flashing. Set
the month with the «ODO/SET» button. Push the «CLOCK» button again and the day
numbers@ start flashing. Set the day with the «ODO/SET» button.
CAUTION
IT IS STRONGLY ADVISED NOT TO USE THE FUNCTIONS OF THE DIGITAL
DISPLAY PANEL WHILE THE VEHICLE IS MOVING.
01_08
*MODE* button (01_08, 01_09)
Hold down the «MODE» button or the remote switch «E» « MODE» for less than one
second to start the following sequence of functions:
1. MEAN SPEED -theword«MEAN»andkm/h ormph isdisplayed.Thevalue
is reset by resetting the trip odometer.
2. MAXIMUM SPEED - The words «MAX» and km/h or mph are displayed.
The value is reset by resetting the trip odometer.
3. BATTERY VOLTAGE - The battery icon is displayed. Should voltage be ab-
normal, the icon is displayed and flashes for 60 seconds.
Hold down the «MODE» button or the remote switch «E» «MODE» for more than 3
seconds to go back to the «1» MEAN SPEED function.
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01_09
N.B.
- MEAN SPEED IS CALCULATED JUST BY TURNING THE KEY TO «ON» AND
THE ENGINE HAS TO BE OVER 800 RPM.
- TO SHIFT FROM km/h TO mp/h: HOLD DOWN THE «MODE» AND «CLOCK»
BUTTONS SIMULTANEOUSLY, WITH THE KEY SET TO «OFF». THEN TURN THE
KEYTO«ON»HOLDING DOWNBOTH BUTTONSFOR MORETHAN 3SECONDS.
WHEN THE WORD «SET» IS DISPLAYED THE UNIT OF MEASUREMENT HAS
BEEN CHANGED.
01_10
Key switch (01_10)
The key switch «A» is located on the knee-guard panel.
SWITCH POSITIONS
ON «1»: Ready to start position, non-extractable key, mechanical antitheft device dis-
abled.
OFF «2»: Ignition disabled, extractable key, mechanical antitheft device disabled.
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LOCK «3»: Ignition disabled, extractable key, mechanical antitheft device enabled.
SADDLE OPENING«4»: Set this position by pressing the key set to OFF and turning
it clockwise.
Locking the steering wheel
Turn the handlebar to the left as far as it will go, turn the key to position «LOCK» and
remove the key.
Releasing the steering wheel
Reinsert the key and turn it to «OFF».
CAUTION
DO NOT TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING.
01_11
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Switch direction indicators (01_11)
Lever «O» towards «1» = left turn indicators switched on;
Lever «O» towards «2» = right turn indicators switched on;
The lever «O» automatically goes back to its «0» position and the indicators remain
on; push the lever «O» to turn them off.
01_12
Horn button (01_12)
Push the button «P» to honk the horn.
01_13
Light switch (01_13)
When the light switch «N» is set to «1», the low-beam light is on. When set to «2»,
the high-beam light is activated. Push the button «L» and the high-beam light is flash-
ed.
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01_14
Start-up button (01_14)
To start the engine, pull either one of the two brake levers and press the starter button
«B».
01_15
Engine stop button (01_15)
The engine can be started when the emergency cut-off switch «F» is set to «1»
RUN; if the emergency cut-off switch «F» is set to «0» OFF , the engine cannot be
started, or it shuts off if it is already running.
The immobilizer system
In order to enhance theft protection, the scooter is equipped with a «PIAGGIO IM-
MOBILIZER » electronic engine locking device that is activated automatically when
the starter key is removed. Upon start-up, the «PIAGGIO IMMOBILIZER» system
checks the starter key, and only if this key is recognised will the immobilizer system
allow the scooter to be started.
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01_16
01_17
01_18
Keys (01_16, 01_17, 01_18)
Two types of keys are supplied together with the vehicle. Key «A» is the «MASTER»
key. Only a single copy of this key is supplied, which is necessary to program the
codes for all your other keys and for your dealer to perform some maintenance oper-
ations. We therefore recommend that it be used only under exceptional circumstan-
ces.
Key «B» (single copy supplied) is used for regular operations such as:
- start-up
- unlocking the fuel tank cover
Together with the two keys, you will be given a CODE CARD bearing the mechanical
code of the keys.
WARNING
LOSING THE RED KEY PREVENTS ANY REPAIRS OF THE 'PIAGGIO IMMOBIL-
IZER' SYSTEM AND THE ENGINE CONTROL UNIT.
WARNING
KEEPTHE'CODECARD'AND THEREDHANDGRIP KEYINASAFEPLACE (NOT
ON YOUR VEHICLE).
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